Coil and method of winding the same



1929. R. VARLEY 1,723,261

' COIL AID IE'I'HOD OF WINDING THE SAIB Filed June 10. 1926 4Sheets-Sheet 1 COIL 2 f ILIYVENTOR.

(M 0/ BY a ATTORNEYJ.

5, 929. R. VARLEY 1,723,261

con. in union or vmmnge was sun Filed June 10. 1926 I 4 Sheets-Sheet 2Call. 1

cm; 1 can. 2

I INVENTOR.

A TTORNEYJ:

1929. R. VARLEY 1,723,261

COIL AND IETHOD 0F WINDING THE SAME Filed June 10. 1926 4 Sheets-Sheet 3can 1 call. a can. can a u com 2 INVENTOR.

' ATTORNEY):

Aug. 6, 1929.

R. VARL EY COIL AND IBTHOD OF WINDING THE SAME Filed June 10. 1926 4Shee ts-Sheet 4 F I N VEN TOR.- My

ATTORNEYJ,

Patented Aug. 6, 1929.

'UNITED'STA'TES PATENT orrlcs.

BICHARD VARLEY, 0F ENGLEWOOD, NEW JERSEY, ASSIGNOR, BY MESNE ASSIGN-MENTS, TOGENERAL CABLE CORPORATION, OF NEW YORK, N. Y., A CORPORATION orNEW messy.

Application filed June 10,

This invention relates generally to coil wind i ng and more s)ecifically to the winding of secondaries of ituhmkortf coils such asare generally used in certain types of ignition systems of internal;combustion motors. This invention is particularly adapted to the windingof coils generally known as multiple winding described in the patent toJ. C. Anderson, N 0. 644,311 issued February 27, 1900, and the articleproduced thereby, and takes advantage of the'cconomy of such type ofwinding to ensure even greatereconomy and saving.

The secondary windings of Ruhmkorfi coils comprises two longitudinallyspaced sections or individual coils mounted upon a common core reverselyto each other so that when their inner ends are connected the two coilsare in simple series. I v

It is well known in the art to wind simul taneously two or more coilsupon the same tube or core but when so doin it is-obvious that theinside wire of one coi must be connected to the outside wire of theother to place the two coils in sim le series. It is also well known inthe win ing art'to mount such a coil by winding a single coil or apluralit of coils upon one portion of a common tu e or tubes, and thento reverse the tube either with or upon its mandrel and wind the secondportion of said coil in the reverse direction of the first wound coil.Thereafter in this method the tubes were removed and the center ends ofthe coils were fished out and connected to each other. In so doing,however, it fre'quentl happened that inner layers of the coils co lapsedduring the fishin rocess. In an attempt to overcome these The wire ofeach coil'was first anchored to the larger tube and the winding comleted, after which the tubi was depre by a blunt steel blade and t estartin end of the windingof each coil was with rawn. The coils with theinner ends exposed were then mounted in a reversesdirection upon anotherinner tube. The two inner ends were then bared, joined, soldered andsecured to the inner tube. This latter method was very inconvenicnt andexpensive besides increasingv the length of the mean turn by creatingconsiderable space not occupied by coil windings.

culties methods were in- V voked using two tubes one within the other.'

1926. Serial No. 114,969.

It is the purpose of this invention to pro vide a method wherebsecondary windings similar to those described may be manufacturedwithout the difiiculties enumerated and in an economical manner and at alow cost and to produce a winding having the inner ends of its coilsconnected in such a manner that the connection is fully protected. Thefinished product contains two coils wound directly in reversedrelationship upon a single core-or tube with their inner endsinterconnected, the jointure lying beneath one of the coils. g a

The present method contemplates winding a plurality of sections eachcomprising one coil or a section of a competed secondary and thenwinding a plurality of other coils forming the other sections of thesecondaries heing made. Any number of coils may be wound at one time aslong as the number is a multiple of tWo. The method will now bedescribed in connection with the drawings which illustrate one form onlyof my invention and in which:

Figs. 1- to 12 illustrate the successive steps involved in the methodembodied in this invention;

Fig. 1 illustrates the first step of the method showing the core mountedupon the. -1n:mdre.l and the wires for two coils attm-hcd;

Fig. 2 shows the coils partly wound;

Fig. 3 illustrates the two coils, each to form one-half of a completewinding, completely wound and ready to have loads attached;

Fig. 4 shows the leads attached and readyto be twisted or strandedterminal wires;

Fig. 5 shows the leads stranded; Fig. 6 shows the leads stranded, cut,the two completed sections cut, and withdrawn from the mandrel;

Fig. 7 illustrates the first step in reversing the coils;

Fig. 8 shows thecoils incompletely reversed positions remounted upon themanwith auxiliary drel and ready to have the second pair of coils wound;

Fi 9 shows the second pair of coils complete wound and ready to haveleads attached;

Fig. 10 shows the leads attached and stranded 1 are cut therein.

3 Figs. 11 and 12 show two completed second ary windings ready toreceive their outer coverings; and

Fig. 13 shows schematically a pair of standard machines each forsimultaneously winding four coils or two complete secondary windings.

In carrying out this invention as illustrated in the accompanyingdrawings the usual paper tube 1 known as the core is mounted upon a twopiece mandrel 2 consisting of an outer shell 2 whichis interiorly boredand threaded and an inner member 3 which is correspondingly'exteriorlythreaded for left hand screw engagement with the outer member. The twomembers may be pinned together by a taper pin 4. A narrow tape 5 oflinen-or other suitable material substantially as long as the mandrelhaving kerfs or tongues cut therein as illustrated, is cementedlongitudinally upon the mandrel. Three tongues 6, 7, 8 being cut closetogether in tandem at suitable distances along the tube, another kerf 9is cut, two more 10, 11 at suitable distances from the opposite end iand one more 12 near the end adjacent to 12,

these kerfs or tongues forming anchoring means for the wire from whichthe coils are wound and may be out directly in the core member.

In starting to make the secondary windings this strip of linen iscemented upon a suitable core, which core may be continuous orsectional, and the above mentioned kerfs The core is then mounted upon atwo piece mandrel and the entire assembly placed in a winding machinewhich for purposes of simplicity will be assumed to be a machine forsimultaneously winding two coils although any multiple of two may bewound at one time. It has been found convenient for one'operator tomanipulate a pair of machines, each one of which simultaneously windsfour coils such as is shown in Fig. 13. The two wires 13, 14 from thesupply spools are led down over suitable guides to the core 1, wire 13from which coil 1 will be wound'is twisted around kerf 8 thence alongkcrf 7 and around tongue 6. Wire 14 from which coil 2 is wound iswrapped around kerf 9 along tongue and is secured around kerf 11 asillustrated particularly in Fig. 1.

'lhe mandrel is then rotated and the wires fed transversely to the righta predetermined distance as illustrated in Fig. 2, when a single sheetof insulating material 18 is positioned to surround each layer of bothcoils and extends over the outer ends of the two coils. The two wiresare then ,fed transversely to the'left to the starting point whenanother sheet of material is placed to en- 'circle the second layer ofeach coil. This cycle is repeated at. each layer of the two coils, thelengths of the sheets of material tween the two coils.

may be varied as the diameters of the two coils increase; however, ithas been found economical to utilize the same size sheet of material.

It is to be noticed that coil 1 is wound on that portion of the corebetween the kerf 8 and a point to the left of kerf 9 leaving the kerfs6, 7, 8 and an unoccupied portion of the tube 1 extending to the left.Coil 2 is wound upon that portion of the core lying between kerfs 9 and10 leaving a portion of the tube including kerfs 10 and 11 extendingunoccupied to the right and leaving a space belVhen the coils havereached a certain size corresponding to a predetermined number of layersthe machine stops, a second strip of linen 15 or any other suitablematerial with kerfs 16, 17 cut therein is cemented over the last layerof insulating material. 18, the pin 4 is withdrawn and the mandrel isrotated by hand for several turns.

- This latter operation causes the last few turns,

seven having been found to be a satisfactory maximum number, to bespaced apart due to the pin 4 having been extracted allowing the outermember 2 of the mandrel to travel laterally of the inner member 3 due totheir threaded engagement. The outer ends of coils 1 and 2 are wrappedaround kerfs 16, 17 and secured thereby, (Fig. 3). The separation of thelast few turns of the coils is for the purpose of preventing breakdownof the coil due to the kick back resulting 'from any impedance in theoutput circuit connected to the secondary windings.

Inasmuch as the wire used for winding the coils is extremely thin it isunsuitable for lead wire, consequently it is necessary to attachheavierlead wires. This is accomplished as shown in Fig. 4.- by wrapping astrand or strands of wire, 19, 20 of the desired size around the kerfs16, 17 soldering these wires to the ends of the coils, which werepreviously wound around the same kerfs, looping the strands throughhooks 21, 22, winding the ends of the leads again around the kerfs, andsoldering. The hooks 21, 22 are rotated by means of gears attached to amotor as illustrated in Fig. 10 or by a manually operable mechanism orany other similar device thereby imparting a twist to the lead wires asshown in Fig. 5 after which they are cut as shown in Fig; 6. The mandrelis again rotated and a cutter is brought into contact with theinsulating sheets so as to sever them through the center. The coils may,however,

be separated after removal from the machine.

The tube or core if not already in two sections is cut by the sameoperation there being- The two coils are removed from the man'- drel andrelatively reversed while the two part mandrel is reassembled and pin 4is reinserted. The reversing of the coils may conveniently beaccomplished as illustrated in Figs. 7 and 8 in the following manner.Coil 2 is placed upon the opposite side of coil 1, see Fig. 7, and thenthe two coils together are turned 180 and replaced upon the mandrel(Fig. 8) thus bringing the unoccupied portions of the two cores togetherat the center between the two wound coils 1 and 2.

The two wires 13, 14, if the same machine is used, are then led down tothe mandrel again and wrapped around the kcrfs 6, 7 and 10, 11respectively which already have the inner ends of coils 1 and 2 securedto them, thus interconnecting the center ends of the two coils. Theseconnections may readily be soldered at this point. Wire 14 is then ledaround kerf 12 and the second two coils are ready to be wound. Themachine is rotated and coils 3 and 1 are wound in a similar manner tocoils 1 and 2. It is to be noted that coils 3 and 4 are wound in adirection opposite to that of coils land 2 due to the fact that coils 1and 2 have been reversed from their original po sition u on the mandrel.Leads 23, 24 are attache to coils-3 and 4 in a similar manner to leads19, 20. The insulating sheets 18 are then cut thus forming two completesecondary windings each comprising two coils with .their centersinterconnected and the coils being wound in the reverse directions. Thetwo windin are now ready to receive their outer protective wrappings.

It can readily be seen that windings manufactured in this manner havethe splice connecting their inner ends placed under the coils and notexposed between the coils, also no fishing or shellacing is necessar asthe original core or tube is used and le t within the coils throughoutthe rocess. With the jointure of the two coils ying under one of thecoils it is impossible for the splice to work out near the surface andthe striking distance is maintained at a maximum.

For purposes of simplicity the above description has been made withreference to four coils or two complete windings. In actual practice ithas'been'found that one operator can conveniently take care of twodouble machines as illustrated in Fig. 13 which machines will producefour complete windings. Coils 1 and 2, 1 and 2' are wound simultaneouslyupon the first machine and after being reversed they are preferablyplaced u on the second machine and coils 3, 4; 3 an 4 are woundsimultaneously while four new coils are being started upon the firstmachine. In Fig. 13 the first machine is shown as starting upon coils 1,2, 1' and 2 whereas the second machine is shown as giving the twist toleads 23, 24, 23' and 24' of coils 3, 4, 3 and 4'. The two lowersketches illustrate the coil windings as they come from the machineready to receive their outer protective coverings.

It is to be understood that various modie the width of the coil to bewound, winding a (oil on said tube in a direction beyond said point,reversing said coil and core, winding a second coil upon the extensionof said tube and wire. and attaching the inner ends of said coils.

2. The method of winding Ruhmkorfi coils or the like which consists insimultaneously winding a plurality of coils upon a common core extendingsubstantially from said coils, inserting sheets of material common totwo coils between layers, severing said material and cores midwaybetween each pair of coils, rotatably reversing said coils relatively tothemselves, attaching lead wires to the outer ends of said coils,connecting the inner ends of each of said coils to the beginning of asecond series of coils to be wound, simultaneously winding a secondseries of coils upon the extended ortions of said core and attachingleads to the outer ends of said second series of coils.

3. The method of winding Ruhmkortf coils or the like which consists incutting a series of kerfs u on a core, securing a pair of wires to two 0said kerfs, extending said wires lon itudinally along the core to apoint laterafiy of where the coils are to begin, simultaneously windinga pair of coils upon said core, rotatably reversing said coils,simultaneously winding a second pair of coils and connecting the innerends of said second series of coils to the extended inner ends of saidfirst mentioned coils.

4. The method of winding Ruhmkortf coils or the like which consists incutting a series of kerfs upon a core, securing a pair of wires to twoof said kerfs, extending said wires longitudinally along the core to apoint where the coils are to begin, simultaneously winding a pair ofcoils upon said core, rotatably revorsing said coils, securing a secondpair of wires to said kerfs and simultaneously winding a second pair ofcoils starting from said kerfs.

5. The method of winding two Ruhmkorfi coils consisting in winding twocoil sections in the same direction in close )roximity upon a core sothat the core exten s substantially outside of each coil section,separating the core with the coil sections thereon between the coilsections, rotatively reversing the coil sections with respect to eachother so as to present the extended ends of the cores together,connecting the inner end of each of said coil sections to the beginningof a second coil section, and simultaneously Winding two other coilsections from said beginnings in the same direction as the first WereWound one uponeach core extension.

' 6. The method of winding two Ruhmkortf coils consisting in winding twocoil sections in the same direction in close proximity upon a commoncore so that the core extends substantially outside of each coilsection, severing the core with the coil sections thereon between thecoil sections, rotatively reversing the coil sections with respect toeach other soas to present the extended ends of the cores together,connecting the inner end of each of said coil sections to the beginningof asecond coil section, and simultaneously winding two other coilsections from said beginnings in the same direction as the first werewound one upon each core extension.

7. The method of winding two Ruhmkortf coils consisting in winding twocoil sections in the same direction in close proximity upon a core sothat the core extends substantially outside of each coil section,inserting sheets of insulating material commonto the two coil sectionsbetween layers thereof, separating the core and insulating material withthe coil sections thereon between the coil sections, rotativelyreversing the coil sections with respect to each other so as to presentthe extended ends of the cores together, connecting the inner end ofeach of said coil sections to the beginning of a second coil section,and simultaneously winding two other coil sections from said beginningsin the same direction as the first were wound one upon each coreextension, inserting sheets of insulating material common t o the lasttwo coil sections two coil sections wound.

RICHARD VARLEY.

and severing the material between the last

